Rear caliper overhaul (Mercedes-Benz S-Class W116)

The caliper halves should not separate during disassembly, since the mounting bolts were tightened to a certain torque during assembly at the manufacturer. To disassemble the caliper, a template is required for the correct installation of the piston in the brake cylinder during assembly.

Remove the brake pads (section 17.2.1).

Using a screwdriver, remove the dust ring.

Using a lever, move the piston until it stops in the brake cylinder. Place a wooden gasket in the cavity of the caliper between the pistons and, holding it with your finger, press out the second piston using compressed air.

Remove the piston sealing ring from the groove in the cylinder. Press out the second piston and remove the piston sealing ring. Fig. 256 shows the piston and its parts.



Clean all parts thoroughly. All instructions for installing the front wheel brakes (section 17.1.3) apply equally to the rear wheel brakes.

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Apply grease to new sealing rings and place them in the grooves of the brake cylinders.



Insert the pistons into the brake cylinders.

Using a template, check the position of the piston relative to the caliper, as shown in Fig. 255. If necessary, turn the piston using pliers.